SURFACES | TECHNOLOGY
a thermoplastic melt is injected after closing the tool. The result is a plastic component with com- plete single-image decoration on the front and a capacitive touch sensor on the back. Ultra-thin, malleable sensors are essential for the
desired freedom when it comes to design creativ- ity. PolyIC specialises in the custom production of metal-mesh touch sensors and relies on extra-thin sensor films, which can also be used in 3D compo- nents with curved surfaces, due to their particular flexibility and robustness. As a carrier, PolyIC uses a transparent plastic substrate (PET) on which high-resolution silver-based metal structures (metal mesh) with a thickness of less than 100 nm and a line width in the low micrometre range are applied in the rolling process. The sensors can later be easily crushed and recycled with the entire compo- nent or added back to the injection moulding process as scrap during production. Bundling the four process steps of decoration, thermoforming, injection moulding and punching requires a versatile system. Kurz worked with Wittmann Battenfeld, which developed an all-in- one concept. The machine manufacturer not only supplies the injection moulding machine but also all peripheral components, such as the parts conveyor system, tool tempering devices and cleanroom housing. This ensures that all devices are optimally coordinated with each other. Innovative injection moulding tools were also supplied by Georg Kaufmann Formenbau. The Swiss company applied its In-Mold Wrapping (IMW) bending and trimming system. Due to the integrated tool technologies, the components are finished during the injection moulding process. IMW technology also enables tool-integrated decoration of the front edge of the component, which does away with the need for subsequent work steps. The all-in-one tool technology enables significant shortening of the process chain and reduces production and logistics costs long term. Consumer brands often favour the use of
recycled, organic or bio-based materials, while not compromising on quality and aesthetics. However, these non-homogeneous materials – mixtures of different batches, impurities and colours – often present difficulties during processing such as appearance defects and mouldability. Roctool has further developed its Heat & Cool technology to provide high surface quality on sustainable resins. By heating the mould by induction, the process allows better flow of the materials inside the mould. It eliminates defects such as weld lines, shrinkage and blush, regardless of whether the parts are thin or thick. The technol-
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ogy also optimises glossy or matt finishes, different contrasts and textures, via the Ultra Surface Replica- tion of up to 97.2% (depending on the material used). Roctool technology is suitable for injection moulding, reduces injection pressure and reduces or eliminates secondary operations. TactoTek, the Finnish company that develops and licences in-mould structural electronics (IMSE) technology, and Amphenol ICC, a global manufac- turer of interconnect products, are collaborating to develop automotive grade in-mould connectors using the IMSE technology. IMSE parts integrate printed electronics and electronic components within 3D injection moulded plastics. They com- bine structure, electronic functions and cosmetics in single piece, seamless smart surfaces. TactoTek IMSE parts often connect to external system electronics or host systems. “Standardised in-mould connectors further simplify integrating IMSE smart surfaces in all types of products, whether vehicles, appliances or smart home solutions,” says Paavo Niskala, Senior VP Research & Development at TactoTek. “In addition, the Amphenol MicroSpace connector enables high speed, automated IMSE production processes for faster cycle times and high yields.”
CLICK ON THE LINKS FOR MORE INFORMATION: �
www.arburg.com �
www.engelglobal.com �
www.verstraete.mcclabel.com �
www.digimarc.com �
www.orkla.com �
www.leonhard-kurz.com �
www.polyic.com �
www.wittmann-group.com �
www.gktool.ch �
www.roctool.com �
www.tactotek.com �
www.amphenol.com
October 2021 | INJECTION WORLD 21
Above: Roctool has developed its Heat & Cool technology to provide high surface quality on sustainable resins
IMAGE: ROCTOOL
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